Original subtitles

--Captions by VITAC-- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

Narrator: THE USE OF GLASS AS AN ARTISTIC MEDIUM

DATES BACK TO ANCIENT EGYPT.

DESPITE THE OBVIOUS FRAGILITY OF GLASS SCULPTURES,

THIS ART FORM HAS AN ENDURING APPEAL.

THE TRANSPARENCY OF GLASS OFTEN HAS A GHOST-LIKE QUALITY.

THEY'RE TANGIBLE WORKS OF ART THAT ARE SKILLFULLY CRAFTED.

WITH THIS GLASS SCULPTURE OF A HORSE,

THE ARTIST'S TWO PASSIONS COME TOGETHER --

ART AND HORSEMANSHIP.

THE ARTIST TAKES INSPIRATION FROM HER HORSE,

OBSERVING THE SWELL OF HIS MUSCLES AS HE ROMPS

IN ORDER TO CREATE THE SAME SENSE OF MOVEMENT IN GLASS.

SHE THEN DRAWS A SERIES OF SKETCHES OF THE HORSE

IN DIFFERENT STANCES.

THESE SKETCHES ARE AN ARTISTIC STUDY.

THEY HELP HER WORK OUT THE SCULPTURE'S FORM

BEFORE ACTUALLY CREATING ONE.

SHE CLEANS SOLID GLASS RODS TO PREPARE THEM FOR SCULPTING.

THIS IS BOROSILICATE GLASS, WHICH IS MORE RESISTANT

TO THERMAL SHOCK THAN OTHER KINDS OF GLASS.

SHE BRINGS THE GLASS INTO THE FLAME OF A TORCH TO SOFTEN IT.

ONCE SOFTENED, SHE CAN FUSE TWO OF THE RODS TOGETHER.

THEN USING TWEEZERS AND FLAT, KNIFE-LIKE TOOLS,

SHE SCULPTS THE GLASS

INTO THE SHAPE OF THE HORSE'S HIPS AND LEGS.

SHE WORKS QUICKLY SO THE GLASS DOESN'T HAVE A CHANCE

TO COOL AND FRACTURE.

SHE ADDS A SMALLER PIECE OF GLASS AND FORMS IT INTO A TAIL.

SHE CONSTANTLY TURNS THE GLASS AS SHE WORKS IT TO MAKE SURE

IT LOOKS GOOD FROM ALL ANGLES.

SHE MELTS GLASS IN FRONT OF THE HIPS TO BUILD UP THE BODY

AND SHAPE THE HORSE'S BELLY, BACK, AND CHEST.

THIS IS INTENSIVE AND PRECISION WORK.

THE PIECE MUST BE EXPOSED TO A WELL-ADJUSTED FLAME

AND CONSTANTLY MOVED

SO IT DOESN'T BECOME TOO HOT AND MELT TOO MUCH.

SHE ADDS GLASS TO THE FRONT AND SCULPTS THE SHOULDERS

AND PART OF THE FRONT LEGS.

SHE REMOVES A LITTLE PIECE OF EXTRA GLASS.

SHE DEPOSITS THE SIZZLING, UNWANTED BIT IN WATER

TO COOL IT DOWN AND DISPOSE OF IT SAFELY.

SHE DOES MORE WORK ON THE FRONT LEGS.

SHE'LL REFINE THEM AND FORM HOOVES LATER,

BUT NOW SHE BAKES THE PARTIALLY SCULPTED GLASS HORSE IN A KILN.

THIS IS THE FIRST ANNEALING,

WHICH REALIGNS MOLECULES TO PREVENT CRACKING.

SHE FORMS THE HEAD AND MANE SEPARATELY FROM THE BODY.

THIS IS MORE INTRICATE WORK.

THE FEATURES ARE MUCH MORE DETAILED,

SO SHE USES SMALLER TOOLS.

ONCE SHE SHAPES THE EYE SOCKETS,

SHE MELTS LITTLE BLOBS OF BLACK GLASS INTO THEM.

SHE SCULPTS THE EYES WITH A FLAT KNIFE.

SHE CARVES CREASES ABOVE THEM TO CREATE AN EYELID EFFECT.

SHE ADDS GLASS FOR THE EARS.

THEN, USING A TOOL CALLED A MASHER,

SHE PINCHES THE EARS TO SQUEEZE THEM THINNER.

SHE HEATS THEM AGAIN.

THIS PROCESS CAN CAUSE THE EARS TO STICK TOGETHER,

SO SHE CUTS THEM TO SEPARATE THEM.

SHE CURLS THE EARS USING TWEEZERS

AND TWEAKS THEIR POSITION ON THE HORSE'S HEAD.

SHE MELTS THE BASE OF THE HEAD TO THE BODY,

AND THEY BECOME ONE.

SHE FUSES MORE GLASS TO THE BACK TO CRAFT A MANE,

AND AFTER ANOTHER ANNEALING, SHE RETURNS TO THE LEGS.

SHE SOFTENS THEM WITH A FLAME AGAIN

AND ADDS DEFINITION TO THE FETLOCK JOINTS.

SHE CUTS THE TIPS TO CREATE A MORE LEVEL SURFACE.

SHE MELTS BLACK GLASS ON TO THE ENDS OF THE LEGS

AND SCULPTS IT INTO THE SHAPES OF HOOVES.

WITH A SERIES OF TOOLS, SHE TWEAKS EACH HOOF

UNTIL SHE'S SATISFIED THIS GLASS HORSE

WILL STAND THE WAY SHE WANTS IT TO.

AFTER ANOTHER ANNEALING, SHE SHINES A POLARIZED LIGHT

THROUGH THE SCULPTURE AND EXAMINES IT FOR STRESSES

THAT COULD COMPROMISE ITS STRUCTURE.

FINDING NONE, THIS GALLOPING WORK OF GLASS ART IS COMPLETE.

IT'S BEEN MADE WITH GREAT CARE AND CARING.

Narrator: TO TURN A REGULAR CAR INTO A RACE CAR,

ONE NEEDS TO CHANGE THE PULLEY SYSTEM MOUNTED TO ITS ENGINE.

FACTORY-INSTALLED PULLEY SYSTEMS ARE HEAVY,

AND THEIR PULLEY-SIZE RATIOS

ARE DESIGNED FOR DRIVING AT LOW SPEEDS.

A RACING PULLEY SYSTEM IS LIGHTWEIGHT

AND HAS PULLEY RATIOS FOR HIGH-SPEED DRIVING.

REPLACING THE FACTORY-INSTALLED PULLEY SYSTEM ON A CAR ENGINE

WITH ONE OF THESE RACING PULLEY SYSTEMS

IS LIKE PUTTING A CAR ON STEROIDS.

THE COMPONENTS OF THIS SYSTEM ARE DETERMINED

BY WHAT THE ENGINE ALREADY COMES WITH.

FOR EXAMPLE, IF THE ENGINE'S WATER PUMP

IS TOO HEAVY FOR RACING,

THIS COMPANY MAKES A LIGHTWEIGHT ONE

ALONG WITH A SIZE-APPROPRIATE PULLEY TO GO WITH IT.

TO MAKE A PULLEY, AN AUTOMATIC SAW

CUTS A PATTY OFF AN ALUMINUM BAR.

WORKERS THEN MOUNT THE PATTY ON A COMPUTER-GUIDED LATHE.

AS THE LATHE SPINS, MULTIPLE TOOLS SHAPE

THE PATTY INTO A PULLEY.

THE FIRST TWO TOOLS DRILL A HOLE IN THE CENTER

AND MACHINE THE OVERALL SHAPE.

THEN, THIS TOOL BORES THE HOLE TO A PRECISE DIAMETER.

THIS TOOL CARVES GROOVES

ALONG THE PERIMETER FOR THE PULLEY BELT.

THIS BROACHING TOOL MAKES 17 VERTICAL GROOVES

INSIDE THE BORED HOLE CORRESPONDING TO GROOVES

ON A SHAFT, LOCKING THE PULLEY IN PLACE.

A WORKER REMOVES THE PARTIALLY-FORMED PULLEY

FROM THE LATHE AND MOUNTS IT ON A COMPUTER-GUIDED MILL.

THE MILL'S FIRST TOOL DRILLS SIX ROUND HOLES.

THE NEXT TOOL RESHAPES THOSE HOLES INTO TRIANGLES

KNOWN AS WINDOWS.

THIS REDUCES THE PULLEY'S WEIGHT.

THE FACTORY SENDS ALL PULLEYS OUT TO A PLATING SHOP

WHICH COATS THE ALUMINUM WITH THE HARD,

BLACK PROTECTIVE FINISH KNOWN AS ANODIZING.

THIS IS A DIFFERENT TYPE OF CRANKSHAFT PULLEY.

TO MAKE IT, THE AUTOMATED SAW FIRST CUTS A PATTY

FROM A SMALLER ALUMINUM BAR.

THEN, A WORKER MOUNTS IT ON A COMPUTER-GUIDED LATHE.

AFTER THE FIRST TOOL EVENS OUT THE SURFACE,

THIS TOOL DRILLS A HOLE THROUGH THE CENTER.

THE NEXT TOOL ENLARGES THAT HOLE.

THE NEXT TOOL CUTS A FEMALE PATTERN INSIDE THE HOLE.

A FEMALE PATTERN HAS GROOVES WHICH RECEIVE

CORRESPONDING PROTRUDING AREAS OF A MALE PATTERN.

THE LATHE THEN TRANSFERS THE PATTY TO ANOTHER SPINDLE

TO EXPOSE THE OPPOSITE SIDE FOR MACHINING.

THE FIRST TOOL SHAPES THE BACK.

THE NEXT ONE CUTS A MALE PATTERN.

WITH A FEMALE PATTERN ON ONE SIDE AND A MALE PATTERN

ON THE OTHER, MULTIPLE PULLEYS CAN BE STACKED AND INTERLOCKED

TO ACCURATELY ALIGN THE SYSTEM.

THE FINAL TOOL CUTS STRAIGHT TEETH FOR A SQUARE-TOOTH BELT.

WHEN AN ORIGINAL ENGINE COMPONENT IS REPLACED

WITH A NEW, SMALLER, AND LIGHTER ONE SUITABLE FOR RACING,

THE FACTORY MUST ALSO MAKE A SMALLER, LIGHTER BRACKET

TO MOUNT THE NEW COMPONENT TO THE ENGINE.

A COMPUTER-GUIDED MILL SHAPES A RECTANGULAR PIECE OF ALUMINUM

CUT BY THE SAME AUTOMATED SAW

THAT CUT THE PATTIES FOR THE PULLEYS.

BRACKETS, LIKE PULLEYS, GO OUT FOR ANODIZING.

WHEN THEY COME BACK TO THIS FACTORY,

THEY GET LASER-PRINTED WITH A BRAND NAME AND MODEL.

HERE'S HOW THE PULLEY SYSTEM

ASSEMBLES ON THIS PARTICULAR ENGINE.

FIRST, THE TECHNICIAN BOLTS AN ADAPTER

TO THE HARMONIC BALANCER.

THE HARMONIC BALANCER IS A COMPONENT

ON ALL ENGINES THAT LESSENS VIBRATION.

NEXT, HE INSTALLS THE NEW CRANKSHAFT PULLEY

ON TO THE ADAPTER, ATTACHING IT WITH A LONG CENTRAL BOLT

THAT EXTENDS BEYOND THE HARMONIC BALANCER

AND INTO THE ENGINE'S CRANKSHAFT.

HE INSTALLS A NEW LIGHTWEIGHT WATER PUMP,

WHICH HAS A NEW MOUNTING BRACKET FOR THE ALTERNATOR

ATTACHED TO ITS LEFT SIDE.

THEN, HE BOLTS ON A NEW WATER-PUMP PULLEY,

WHICH HAS GROOVES FOR TWO BELTS.

AFTER MOUNTING A NEW LIGHTWEIGHT ALTERNATOR,

HE CONNECTS THE WATER-PUMP PULLEY TO THE CRANKSHAFT

AND POWER STEERING PUMP PULLEYS WITH ONE BELT

AND TO THE ALTERNATOR PULLEY WITH ANOTHER BELT.

THIS ALLOWS SIMULTANEOUS STEERING, BATTERY CHARGING,

AND WATER CIRCULATING TO COOL THE ENGINE.

Narrator: COILED COPPER DEVICES CALLED INDUCTORS

PROVIDE STORAGE FOR ELECTRICAL CIRCUITS.

AS ELECTRICAL CURRENT FLOWS THROUGH THE COILS,

A MAGNETIC FIELD IS PRODUCED.

THE INDUCTOR STORES THE ELECTROMAGNETIC ENERGY

UNTIL THE CIRCUIT IS READY FOR IT.

THEY'RE ONE OF THE MOST IMPORTANT PARTS IN THE CIRCUIT.

INDUCTORS COME IN MANY SHAPES AND SIZES.

CONDUCTIVE WINDINGS SURROUND AN IRON-BASED CORE

TO PROVIDE TEMPORARY ENERGY STORAGE

AND TO REGULATE THE CURRENT FLOWING THROUGH A CIRCUIT.

TO MAKE AN INDUCTOR, MANUFACTURES USE

PLENTY OF FLAME-RESISTANT INSULATING MATERIAL.

THEY CUT SHEETS OF IT TO THE DESIRED DIMENSIONS.

AN OPERATOR PROGRAMS THIS AN AUTOMATIC SHEAR

TO CUT THE ELECTRICAL INSULATION INTO LONG STRIPS.

THE HYDRAULICALLY DRIVEN BLADE MAKES CLEAN, STRAIGHT CUTS.

THESE STRIPS WILL BE USED TO INSULATE THE INDUCTOR CORE

AND COILS.

A WORKER FOLDS A RECTANGULAR PIECE OF INSULATION

AROUND AN ALUMINUM FORM TO START THE INDUCTOR COIL.

SHE TAPES THE ENDS TOGETHER.

SHE PULLS A STRIP OF COPPER FOIL TO THE INSULATION.

SHE'S PRE-SOLDERED A TERMINAL TO THE END OF THE FOIL,

AND SHE TAPES THE TERMINAL TO THE INSULATING MATERIAL.

SHE BEGINS TO WIND THE COPPER FOIL

AROUND THE INSULATING MATERIAL AND STOPS.

SHE PLACES ONE OF THE LONG INSULATING STRIPS

UNDER THE COPPER FOIL AND RESUMES WINDING.

THIS PREVENTS SHORT CIRCUITS.

SHE CLAMPS THE COPPER WINDINGS TIGHTLY TOGETHER

AND TUCKS AN EXTRA PIECE OF THE INSULATION UNDER THE COPPER.

SHE HAMMERS THE COPPER TO FLATTEN ANY KINKS.

SHE SOLDERS A SECOND TERMINAL

TO THIS END OF THE COPPER FOIL WINDINGS.

THESE TERMINALS WILL BE USED TO CONNECT THE INDUCTOR

TO THE ELECTRICAL CIRCUIT.

SHE HOLDS THE TERMINAL IN PLACE WITH A METAL DOWEL

AND THE SOLDERING IRON UNTIL THE SOLDER SOLIDIFIES.

SHE THEN CUTS THE COPPER STRIP ALONG THE EDGE OF THE TERMINAL.

SHE APPLIES FIBERGLASS TAPE TO THE SOLDERED TERMINAL JOINT.

SHE REMOVES THE CLAMP AND ADDS MORE TAPE

TO KEEP THE TERMINAL IN PLACE.

SHE THEN WINDS FIBERGLAS TAPE

AROUND THE INSIDE OF THE INDUCTOR COIL.

THIS OUTER WRAP WILL PREVENT SHOCKS TO ANYONE WHO MIGHT TOUCH

THE INDUCTOR WHEN IT'S PART OF AN ELECTRICAL CIRCUIT.

USING A TOUGH NYLON BLOCK TO ABSORB THE IMPACT,

SHE HAMMERS THE INDUCTOR COIL TO MAKE IT MORE RECTANGULAR.

SHE REMOVES THE COIL FROM THE WINDING MACHINE.

NEXT UP IS THIS HARD, POLYESTER-INFUSED FIBERGLASS.

MANUFACTURERS WILL ULTIMATELY USE IT

TO INSULATE THE CORE AND FILL THE GAPS.

WITH A HYDRAULIC SHEAR, A WORKER CUTS THE FIBERGLASS

INTO STRIPS THAT WILL FIT IN THE CORE.

ANOTHER WORKER CLAMPS TWO OF

THE INSULATED COPPER WINDINGS SIDE BY SIDE.

SHE INSERTS A C-SHAPED IRON CORE

IN ONE END OF THE COPPER WINDINGS

AND FLIPS THE INDUCTOR ASSEMBLY OVER.

SHE CONNECTS THE PROTRUDING TERMINALS

WITH A TIN-COPPER JUMPER.

SHE INSERTS INSULATING SPACERS INTO BOTH CAVITIES.

THESE FIBERGLASS SPACERS WILL FILL THE GAP

BETWEEN THE TWO IRON "C's."

SHE INSTALLS THE SECOND HALF OF THE IRON CORE.

WHEN ALTERNATING CURRENT IS APPLIED TO THE COPPER WINDINGS,

IT WILL CREATE A MAGNETIC FIELD IN THIS CORE,

AND THIS IS HOW THE ENERGY WILL BE STORED.

SHE TUCKS A COUPLE OF FIBERGLASS INSULATING SPACERS BETWEEN

THE IRON "C's" AND THE COILS.

SHE DRIVES THEM DEEPER INTO THE INDUCTOR.

SHE LOOPS A STAINLESS-STEEL BAND AROUND THE IRON CORE

AND PULLS IT TIGHT WITH PNEUMATIC TENSIONING TOOL.

SHE SOLDERS THE ENDS OF THE BAND TO SECURE IT.

WORKERS IMMERSE THE INDUCTOR IN A VAT OF VARNISH

UNDER VACUUM PRESSURE.

THE VARNISH COMPLETELY SEALS THE INDUCTOR

AGAINST DIRT AND MOISTURE.

THIS INSTRUMENT DETECTS ANY PROBLEMS WITH THE INSULATION.

IT'S ONE OF SEVERAL TESTS CONDUCTED.

IF THE INDUCTOR PASSES THEM ALL,

IT'S READY FOR THE ELECTRICAL CIRCUIT.

Narrator: A MEDICINE BALL HAS NOTHING TO DO WITH MEDICINE

BUT EVERYTHING TO DO WITH HEALTH.

THIS HEAVY BALL IS AN EFFECTIVE WORKOUT TOOL,

AVAILABLE IN A VARIETY OF SIZES AND WEIGHTS.

IT CAN BE USED FOR A WIDE RANGE OF EXERCISES TO IMPROVE

STRENGTH, COORDINATION, AND CARDIOVASCULAR FITNESS.

MEDICINE BALLS ARE MASS-PRODUCED IN A VARIETY OF MATERIALS.

THIS COMPANY IS ONE OF THE FEW REMAINING

WHICH CRAFT TRADITIONAL LEATHER MEDICINE BALLS ENTIRELY BY HAND.

THE CRAFTSMAN USES SHOE LEATHER,

WHICH IS THICKER AND STURDIER THAN GARMENT LEATHER.

HE PLACES A PATTERN ON TOP

AND CUT LOOSELY AROUND IT WITH THE UTILITY KNIFE.

THIS STEEL-CUTTING DIE PRECISION-SHAPES THE PANEL.

THE CRAFTSMAN PLACES IT ON THE ROUGH-CUT PANEL.

THEN, WITH A PRESS, FORCES THE SHARP DIE THROUGH THE LEATHER.

THE BALL IS MADE UP OF SEVEN PANELS LIKE THIS ONE.

ONCE HE HAS CUT ALL SEVEN, HE REPEATS THE PROCESS

WITH THE CIRCULAR PATTERN, THEN A CIRCULAR DIE.

THIS CUTS TWO LEATHER CIRCLES -- ONE FOR EACH END OF THE BALL.

HE CUTS IDENTICAL PIECES FROM NYLON CLOTH.

THESE PIECES WILL LINE THE SEVEN PANELS AND TWO CIRCLES.

FOR THE CIRCLE LININGS, HE FIRST HAND-CUTS SQUARES.

THEN HE CUTS THOSE SQUARES INTO CIRCLES WITH THE DIE.

HE CLAMPS EACH LINING TO ITS CORRESPONDING

LEATHER PIECE AND SEWS THEM TOGETHER

WITH HEAVY-DUTY POLYESTER THREAD.

THIS INDUSTRIAL SEWING MACHINE IS KNOWN AS

A CYLINDER BED MACHINE BECAUSE THE SEWING SURFACE

IS CYLINDRICAL RATHER THAN FLAT,

WHICH ENABLES WORKING WITH A THREE-DIMENSIONAL SHAPE.

HE TAKES TWO OF THE LINED PANELS, AND ONE AT A TIME,

PUTS THEM BACK ON THE PRESS,

THIS TIME USING A DIFFERENT CUTTING DIE.

IT CUTS A NOTCH IN EIGHT LACE HOLES.

HE THEN PLACES ONE OF THESE PANELS IN AN EMBOSSING PRESS,

WHICH HEAT-STAMPS THE BRAND NAME INTO THE LEATHER.

USING DIFFERENT DIES, HE CUTS PIECES OF VINYL

TO REINFORCE THE LACE HOLES, THEN SEWS THEM TO THE PANELS.

THIS IS THE ONLY AREA WHERE THE BRIGHT RED THREAD

WILL BE VISIBLE.

HE SEWS THE PANELS TO EACH OTHER UNTIL HE'S FORMED

A CLOSED CIRCLE.

HOWEVER, HE DOESN'T YET STITCH TOGETHER

THAT NOTCHED AREA BETWEEN THE TWO SETS OF LACE HOLES.

FIRST, HE SEWS THE LINED LEATHER CIRCLES TO THE ENDS.

THE BALL'S LEATHER SHELL IS COMPLETE,

BUT INSIDE OUT AND WITH A GAP BETWEEN THE LACE HOLES.

THE CRAFTSMAN HANDS IT OFF TO A COLLEAGUE

WHO INVERTS THE SHELL AND PRESSES THE SEAMS AGAINST

A METAL ROD TO STRETCH AND ROUND THEM OUT.

NOW IT'S TIME TO STUFF THE SHELL.

THE WORKER TAKES SHREDDED SCRAPS OF LEATHER,

INSERTS THEM THROUGH THE GAP BETWEEN THE LACE HOLES,

THEN COMPRESSES THE SCRAPS WITH A THICK WOODEN DOWEL.

ONCE THE BALL IS FULLY STUFFED,

HE MAKES SURE THE BALL HAS REACHED THE TARGET WEIGHT.

WEIGHT PRECISION, HOWEVER,

IS LESS IMPORTANT THAN PERFECT ROUNDNESS.

TO CLOSE UP THE BALL, HE THREADS A THICK RAWHIDE LACE

THROUGH A LARGE BRASS NEEDLE

AND THREADS IT THROUGH THE LACE HOLES, PULLING TIGHTLY.

THIS IS THE SAME STURDY LACING CONFIGURATION

THAT'S USED ON FOOTBALLS.

HE USES TWO LARGE, THICK NAILS TO PROPERLY SIZE THE END LOOPS.

THEN HE SNIPS OFF THE EXCESS LACE.

AND POKES EACH END INSIDE A LACE HOLE.

NOW HE CAN SAFELY REMOVE THE NAILS.

WITH A FINAL POUNDING HERE AND THERE TO PERFECT THE SHAPE,

THIS MEDICINE BALL IS READY TO PULL ITS WEIGHT

IN SOMEONE'S EXERCISE REGIMENT.